Weatherstrip and method for sealing a gap

ABSTRACT

A weatherstrip and method for sealing a gap comprising a base preferably of fabric material, and one or more sealing bodies such as rows of pile fibers extending longitudinally there along. A barrier strip formed of a thin film or sheet of flexible plastic material is secured at one edge to the base and/or sealing bodies and projects substantially above the free or upper ends of the pile members. Foamed cellular plastic bodies may be used in place of the bodies of pile fibers, or a single body of pile or foamed plastic material may be used with the barrier strip located on one side thereof.

TECHNICAL FIELD

This invention relates to weatherstrips and methods for sealing gaps orjoints such as those between doors, windows and other enclosures, andthe frames of structural supports therefore. While such weatherstripsare capable of use in various places for various sealing orweatherstripping purposes, they are particularly suitable for use onwood or aluminum windows and doors for sealing or weatherstripping thesmall clearance openings between adjacent door panels or window panelsor between the panels and the frames in which they are mounted orbetween the door edge and an adjacent surface such as a floor. Moreparticularly, this invention relates to weatherstripping having a baseof indefinite length from which project preferably filament membersforming a pile along the length of the base, and a flexible barriermember located within or beside the pile and extending along the lengthof the pile to aid in sealing the joint.

BACKGROUND ART

It is well known to provide a weatherstrip having rows of pile extendinglongitudinally from a flexible base, and having a substantiallyimpervious barrier comprising a thin film or sheet of plastic materialsecured to the base and/or to the pile to supplement the sealing actionof the pile and increase the resistance to air infiltration through theweatherstrip. An example of this construction is shown in U.S. Pat. No.3,175,256 in which the barrier member is located between adjacent rowsof pile. It is also known to locate the barrier strip on one side of thebody of pile as shown in U.S. Pat. No. 3,404,487, or on both sides ofthe pile as shown in U.S. Pat. No. 3,266,190. U.S. Pat. No. 3,745,053discloses a weatherstrip having longitudinally extended rows of pilewith an impervious barrier strip located between adjacent rows of pileand secured only to the pile.

However, in all of the weatherstrips having pile and a supplementalplastic film or sheet forming a substantially impervious barrier, it hasbeen common practice to form the weatherstrip so that the plastic sheetis substantially the same height as the pile, or slightly below theheight of the pile, or in certain instances, slightly above the pileheight. However, in all cases, the differential in height between theupper edge of the plastic barrier and the pile has been minimal andthese parts have been of substantially the same height. It has beenfound that despite the advantages of the plastic film in reducing airand moisture infiltration through the weatherstrip, the film increasesthe break-away force required to open the sliding window or door.Break-away force is defined as the force required to overcome theinertia of the window or door when starting from a fully closedposition. The film tends to snap over or reverse itself as the slidingwindow or door is moved from a fully closed position, thereby increasingthe resistance to such movement to the point that the break-away forcerequired to open a door or window has become excessive. Hence, smallchildren or elderly people often cannot open the windows or doors havingsuch weatherstripping.

This invention has for its primary object the provision of aweatherstrip and method for sealing a gap which, although having a thinfilm or sheet of plastic, or the like, reinforcing the pile bodies toimprove the resistance to air moisture infiltration, is so constructedthat the opening or break-away force is significantly reduced whilemaintaining desired sealing properties. It has been found that thebreak-away force can be reduced by eliminating the plastic barriermember or by shortening it so that it is substantially lower in heightthan the top of the pile so that when the pile is compressed to theusual degree of approximately 20%, the barrier strip is notsubstantially bent or flexed. Although such a construction reduces thebreak-away force, it does not provide satisfactory sealing properties asthe resistance of the weatherstrip to water and air infiltration ismarkedly reduced and an unsatisfactory seal results.

DISCLOSURE OF INVENTION

In accordance with the present invention, a weatherstrip and method isdisclosed for sealing a gap between members such as doors, windows,joints or the like which are movable relative to one another betweennon-aligned and aligned positions. The weatherstrip has a backing stripfor securing the weatherstrip to one of the members. At least onesealing body has one end portion fixed to one face of the backing stripand extends longitudinally thereof to form a sealing assembly. Thesealing body extends from the face toward the other member tosubstantially close the gap between the members. A flexible film ispositioned transverse to the face and is fixed adjacent one edge thereofto the sealing assembly. The opposite free edge of the film extendsbeyond the opposite free end portion of the sealing body for asubstantial distance whereby the free edge of the film is bent over atleast a part of the free end portion of the sealing body when themembers are moved to their aligned position.

In other aspects of the invention, the free edge of the film extendsbeyond the free end portion of the sealing body a distance of between.[.0.015.]. .Iadd.0.050 .Iaddend.inches to 0.200 inches, and preferablyapproximately 0.100 inches. Also, the sealing body comprises a body ofup-standing flexible and resilient fibers. The flexible film issubstantially impervious and located between a pair of sealing bodies.

The advantages of the weatherseal of this invention are, among otherthings, to (1) reduce the break-away force required to move a door,window or the like from a fully closed position and (2) reduce air andmoisture infiltration through the weatherseal.

BRIEF DESCRIPTION OF DRAWING

In the detailed description of the preferred embodiments of theinvention presented below, reference is made to the accompanyingdrawings, in which:

FIG. 1 is a perspective view of a weatherstrip embodying the presentinvention;

FIG. 2 is a view similar to FIG. 1 showing the position of theweatherstrip during a manufacturing step;

FIG. 3 is a sectional view of the weatherstrip shown in FIG. 1 takensubstantially along line 3--3;

FIG. 4 is a view similar to FIG. 3, but showing the weatherstripassembled on one of two relatively movable members;

FIG. 5 is a fragmentary view in section showing the two relativelymovable members to be sealed by a weatherstripping;

FIG. 6 shows the weatherstripping of FIG. 4 in position on one of therelatively movable members and the other member brought into positionwhereby it is contacted by said weatherstripping;

FIG. 7 is a view similar to FIG. 6, but showing the prior artweatherstripping in sealing position between two relatively movablemembers;

FIG. 8 is a view similar to FIG. 5, but showing another type of mountingfor said weatherstrip;

FIG. 9 is a sectional view of a weatherstrip similar to FIG. 3 mountedwithin an inverted T-shaped slot as shown in FIG. 8 in one of saidrelatively movable members; and

FIGS. 10-19 are views similar to FIG. 3, but showing modifiedembodiments of the weatherstrip.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to FIGS. 1-3 of the drawings, the preferred embodiment ofthe weatherstrip of the invention is generally designated at 20 andcomprises a backing or base strip 22 which, in one of its forms, iswoven of textile fibers, either natural or synthetic, as is well knownin the art. This base strip preferably has formed thereon bodies ofup-standing resilient long pile fibers 24 which may be either cut orleft un-cut. Such fibers may be of known plastic materials such aspolypropylene, nylon, orlon, or may be made of natural fibers such asmohair, goat hair, wool, jute or the like, or any combination thereof.Base strip 22, is preferably formed by weaving, although the pile fibersmay be fixed thereto by mechanical embedments, flocking, tufting orother known methods. Base strip 22 preferably has its marginal edgesextending beyond the pile bodies as at 25 for ease in mounting the stripas is well known in the art. Base strip 22 is preferably formed with anarrow longitudinally extending gap or "skip" 26 intermediate itsmarginal edges, for a purpose which will be described hereinafter.

Base strip 22 is preferably given a coating of known polymeric materialsuch as polypropylene, to protect it against abrasion, to stiffen it,and to facilitate the cutting of the strip without fraying.

A barrier strip 28 comprising a relatively thin flexible film or sheetof a known organic or inorganic thermoplastic or thermo setting materialsuch as vinyl, nylon, glass fiber fabric coated with vinyl,polypropylene, polyethylene, or other known material is preferablysecured adjacent its lower edge to base 22 along gap 26 by heat welding,by suitable adhesives or by other known means as is well understood inthe art. Barrier strip 28 may also be secured to the adjacent pilefibers in addition to or instead of being attached to base 22, as iswell known in the art. Barrier 28 is thus resiliently supported alongthe base and serves to increase the resistance of the weatherstrip towind, rain or other elements that might otherwise penetrate theweatherstrip. While barrier strip 28 preferably comprises a film foldedupon itself to form two leafs with the fold at the bottom, single ordouble leafs may be used as well.

FIG. 2 shows the pile bodies and barrier strip spread apart for ease insecuring the barrier strip to the base strip and/or adjacent pilefibers.

While barrier strip 28 is preferably of an impervious plastic material,it also can be formed of woven or non-woven or matted material which,while not totally impervious, is substantially impervious to wind andmoisture under the conditions to which the weatherstripping is normallysubjected.

FIG. 4 shows the weatherstripping affixed to one of the relativelymovable members 32 and 34 which are to be sealed by theweatherstripping. The members 32, 34 may be portions of a window, door,joint or the like.

FIG. 5 shows members 32 and 34 in a closed or aligned position whereinthe letter D indicates the distance or spacing between members 32 and34, which spacing is to be sealed by the weatherstripping. In thisillustration, member 34 has been moved laterally in the direction of thearrow into the aligned position.

It has heretofore been the practice when using weatherstripping forsealing such openings between members such as 32 and 34 to select aweatherstripping in which the bodies of pile fibers extend above thebase strip 22 by a distance greater than distance D. Accordingly, whenthe weatherstripping is in an aligned sealing position, the pile fibersand barrier are subjected to a compression of approximately 15% to 30%,this being measured by the height of the fibers in normal relaxedposition and the height of the fibers in their compressed position. Sucha condition is shown in FIG. 7 wherein parts similar to those in FIG.4-6 are indicated by numbers being 100 units higher. As shown in FIG. 7,the pile fibers 124 are under considerable compression and are bent overand the barrier 128 is similarly bent by the compression between parts132 and 134. Under these conditions, while adequate sealing againstwater and air infiltration may occur, the break-away force isexcessively high and renders the window or door unopenable by smallchildren and elderly people. Such break-away forces may exceed 60 poundson a normal sliding glass door.

In the present instance, the height of the pile 24 measured from thebottom of base 22 is selected so that the pile extends substantially tomember 34, that is substantially equal to the distance D, but is notmaterially compressed or deflected by member 34 when members 32 and 34are in opposed or aligned positions as shown in FIG. 6. Since barrierstrip 28 extends substantially beyond the free ends of pile bodies 24,it is caused to bend in the direction of motion of member 34 relative tomember 32 and lies over the top of the pile fibers on the right handsealing body and forms a continuous barrier against air and waterinfiltration thereby providing the desired sealing action. This"laying-over" of member 28 is easily accomplished during the movement ofmember 34 in the direction of the arrow relative to member 32. Inaddition, when member 34 forms a part of a door, window or the like andis moved in the opposite direction so as to open the door or window,barrier 28 does not flip over and thus does not add to the openingresistance. Moreover, since pile bodies 24 are under substantially nocompression or may even be under a negative compression, that is, theydo not quite touch member 34, the break-away force needed to move member34 is markedly reduced while at the same time providing an improvedweatherstripping that creates an effective seal. Thus, by reducing theheight of the pile bodies so that when in sealing position said bodiesare under substantially no compression and by extending barrier strip 28well beyond the upper ends of said pile bodies an improved seal isproduced. It has been found that while barrier 28 may extend from.[.0.015.]. .Iadd.0.050 .Iaddend.inches .[.0.038.]. .Iadd.0.127.Iaddend.centimeters) to 0.200 inches (0.508 centimeters) above the freeends of pile bodies 24, the preferred extension of barrier strip 28above pile members 24 is substantially 0.100 inches (0.254 centimeters).Thus, the optimum conditions are substantially zero or negativecompression of pile bodies 24 when in sealing position with barrierstrip 28 extending approximately 0.100 inches (0.254 centimeters) beyondthe free ends of said pile members.

FIGS. 8 and 9 show a pair of relatively movable members 232 and 234 inwhich member 232 is formed with in inverted "T"-shaped slot 30 providingopposed recesses 31 for the reception of marginal edges 25 of base 22 ofweatherstripping 20. In FIG. 8 the letter D' indicates the distance orspacing between members 232 and 234, which spacing is to be sealed bythe weatherstripping. FIG. 9 shows a weatherstripping of the type shownin FIGS. 1-3 mounted within a slot 30 of the type shown in FIG. 8.

While it is preferable to provide sealing bodies of pile fibers 24 oneach side of barrier strip 28 as shown in FIGS. 1-3, it is sufficientfor certain installation to provide only a single body of pile fibers 24on one side of barrier strip 28. Such a construction is shown in FIG. 10wherein an arrow 36 indicates the direction of the movable member (notshown) relative to the member on which base 22 is mounted. In thisconstruction, the movement of the movable member in the direction ofarrow 36 folds or bends barrier member 28 over the upper ends of pilemembers 24 similar to that shown at the right portion of FIG. 6. Thus,barrier strip 28 may be located at one side of the pile bodies 24.

FIGS. 11-13 show further modifications in which a barrier strip 28 islocated between or on one side of solid or hollow sealing bodies 38,38', and 40. Barrier 28 performs in the same manner as in FIG. 10, andis bent over the upper edge of a sealing body when the movable membersare brought into aligned or closed positions.

It has also been found that although it is preferable to locate barrierstrip 28 between sealing bodies 24 of woven or flocked pile fibers, thesealing bodies may be formed of resilient, matted or foamed plastic orrubber material, of closed or open cell construction such as spongerubber, polymeric foams or other known and suitable materials ofsuitable density. Such sealing bodies 38, 38', and 40 (FIGS. 11-13), mayhave a round, square or other suitable cross-sectional shape. Bodies 38are formed with a hollow center to aid in providing the desiredresiliency. Bodies 38, 38' and 40 are secured to base 22 by heatwelding, adhesives or other suitable means. Sealing bodies arepreferably selected to have a height from the bottom of base member 22substantially equal to distance D shown in FIG. 5 in the same manner asthe weatherstripping shown in FIG. 6.

FIG. 14 shows a weatherstrip in which a barrier strip 228 is formed froma single film or sheet secured adjacent its lower edge by any suitablemeans to base 22 or to adjacent pile fibers 24.

FIG. 15 shows a weatherstrip similar to the weatherstrip shown in FIG.14 in which the barrier strip 228 is formed integral with base 22,preferably by an extrusion molding operation.

FIG. 16 is also similar to FIG. 14 and shows a pair of spaced apartstrips 228 which may be secured to or integral with the sealing assemblycomprising base 22 and sealing bodies 24.

FIGS. 17-19 relate to a different form of weatherstripping in which abase 222, 322 or 422 is provided having a round or square cross-section.The base is slidably mounted within a complementary slot (similar toslot 30) of one of two relatively movable members, not shown. Each baseis further provided with a V-shaped groove 40 terminating in anelongated central slot 42 for receiving the ends of pile fibers 224 andbarrier strip 328. The fibers are secured adjacent their ends to thebase by any suitable means, and the barrier strip is also secured to thebase and/or to the adjacent pile fibers 224. In FIGS. 18 and 19, grooves40 and bases 322 and 422 are oriented 45 degrees relative to oneanother.

This invention has been described in detail with particular reference topreferred embodiments thereof, but it will be understood that variationsand modifications can be effected when the spirit and scope of theinvention without departing from the terms of the invention.

I claim:
 1. A weatherstrip for sealing a gap between members movablerelative to one another between non-aligned and aligned positions, saidweatherstrip comprising:A. a backing strip for securing saidweatherstrip to one of said members; B. at least one sealing body havingone surface portion thereof fixed to one face of said backing strip andextending longitudinally thereof and cooperating therewith for forming asealing assembly, said sealing body extending from said face toward theother of said members to substantially close said gap between saidmembers; and C. A flexible film fixed adjacent one edge portion thereofto said sealing assembly with said film transverse to said one face, theopposite free edge portion of said film extending beyond said oppositefree surface portion of said sealing body for a substantial distancewhereby said free edge portion of said film is bent over at least a partof said free surface portion of said sealing body when said members aremoved to said aligned position.
 2. A weatherstrip as specified in claim1 in which there are at least a pair of sealing bodies fixed to said oneface of said backing strip, and said flexible film is located betweensaid sealing bodies.
 3. A weatherstrip as specified in claims 1 or 2 inwhich said opposite free edge portion of said flexible film extendsbeyond said opposite free surface portion of said sealing body or bodiesby a distance of between .[.0.015.]. .Iadd.0.050 .Iaddend.inches and0.200 inches.
 4. A weatherstrip as specified in claim 2 in which each ofsaid sealing bodies comprises a body of upstanding, flexible resilientfibers fixed at one end surface thereof to said face of said backingstrip.
 5. A weatherstrip as specified in claim 4 in which said oppositefree edge portion of said flexible film extends beyond the opposite freeend surface of said fibers by a distance of from .[.0.015.]. .Iadd.0.050.Iaddend.inches to 0.200 inches.
 6. A weatherstrip as specified inclaims 4 or 7 in which said opposite free edge portion of said flexiblefilm extends beyond said opposite free end surface of said fibers byapproximately 0.100 inches.
 7. A weatherstrip as specified in claim 1 inwhich said sealing body comprises a body of up-standing flexible andresilient fibers fixed at one end surface thereof to said face of saidbacking strip.
 8. A weatherstrip as specified in claim 7 in which saidopposite free edge portion of said flexible film extends beyond theopposite free end surface of said fibers by a distance of from.[.0.015.]. .Iadd.0.050 .Iaddend.inches to 0.200 inches.
 9. Aweatherstrip as specified in claims 1 or 2 in which said opposite freeedge portion of said flexible film extends beyond said opposite freesurface portion of said sealing body or bodies by approximately 0.100inches.
 10. A method of sealing a gap between members movable relativeto one another between non-aligned and aligned positions, said methodcomprising:A. Affixing a backing strip of a weatherstrip to one of saidrelatively movable members, said backing strip having at least onesealing body having one surface portion thereof fixed to one face ofsaid backing strip and extending transversely and longitudinally thereofand cooperating therewith for forming a sealing assembly; B. selectingsaid sealing body of a size so that the opposite free surface portion ofsaid sealing body when said one surface portion thereof is fixed to saidbacking strip substantially closes said gap between said members; and C.affixing a flexible film to said sealing assembly adjacent one edgeportion of said film with said film positioned adjacent said sealingbody and extending .[.transverse to.]. .Iadd.transversely .Iaddend.saidone face of said backing strip, and the opposite free edge portion ofsaid film .[.extend.]. .Iadd.extending .Iaddend.beyond the opposite freesurface portion of said sealing body for a substantial distance wherebysaid film is bent over at least a part of said opposite free surfaceportion of said sealing body when said members are moved to said alignedposition.
 11. A method according to claim 10 wherein said opposite freeedge portion of said film extends beyond said opposite free surfaceportion of said sealing body a distance of from .[.0.015.]. .Iadd.0.050.Iaddend.inches to 0.200 inches.
 12. A method according to claim 10wherein said opposite free edge portion of said film extends beyond saidopposite free surface portion of said sealing body a distance ofapproximately 0.100 inches.
 13. A method according to claim 10 whereinsaid one sealing body comprises a body of up-standing flexible andresilient fibers fixed at one end surface thereof to said face of saidbacking strip, and the opposite free edge portion of said film extendsbeyond the opposite free end surface of said fibers a distance of from.[.0.015.]. .Iadd.0.050 .Iaddend.inches to 0.200 inches.
 14. A methodaccording to claim 10 wherein there are at least a pair of sealingbodies fixed to said one face of said backing strip, each of saidsealing bodies comprises a body of up-standing flexible and resilientfibers fixed at one end surface thereof to said face of said backingstrip, and said flexible film is substantially impervious and locatedbetween said sealing bodies with said opposite free edge portion of saidfilm extending beyond said opposite free end surface of said fibers adistance of approximately 0.100 inches.